Self-shaping support for flexible materials

ABSTRACT

A self-shaping support for the mechanical support of flexible materials, such as tubular shaped fabric members used for filtration tubes. The support may be comprised of a T-shaped extruded member having a plurality of notches cut in the leg of the T and a plurality of slots punched in each side of the top of the T-shaped member. The support may be sewn to the fabric in the flat condition by stitching through the plurality of slots punched in the top of the T and later rolled into a closed shape by bending so as to close at least a portion of the notches in the leg. A special clip is disclosed for retaining the ends of the support, one with respect to the other. Thus, the fabric tube may be sewn into a shape of a conduit by a longitudinal stitch and the support bent and locked in the desired configuration as each support is approached during the longitudinal sewing operation.

United States Patent, [191 Levor June 18, 1974 [76] Inventor: Henry Levor, 7756 Bumet Ave,

Van Nuys, Calif. 91405 [22] Filed: Feb. 22, 1972 [21] Appl. No: 227,869

[56] References Cited UNITED STATES PATENTS 2,355,707 8/1944 DeBoer 52/656 2,830,683 4/1958 Griffith 52/656 3,466,824 9/1969 Troutner 52/656 Primary Examiner-Charles W Lanham Assistant ExaminerJames R. Duzan Attorney, Agent, or FirmSpensley, Horn and Lubitz 5 7] ABSTRACT A self-shaping support for the mechanical support of flexible materials, such as tubular shaped fabric members used for filtration tubes. The support may be comprised of a T-shaped extruded member having a plurality of notches cut in the leg of the T and a plurality of slots punched in each side of the top of the T-shaped member. The support may be sewn to the fabric in the flat condition by stitching through the plurality of slots punched in the top of the T and later rolled into a closed shape by bending so as to close at least a portion of the notches in the leg. A special clip is disclosed for retaining the ends of the support, one with respect to the other. Thus, the fabric tube may be sewn into a shape of a conduit by a longitudinal stitch and the support bent and locked in the desired configuration as each support is approached during the 1ongitudinal sewing operation.

10 Claims, 16 Drawing Figures SELF-SHAPING SUPPORT FOR FLEXIBLE MATERIALS BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of mechanical devices for supporting non-rigid materials, and particularly to support rings as commonly used in filtration tubes and the like.

2. Prior Art In certain items manufactured from fabric or other non self-supporting materials, it is common practice to use a metal or other rigid supporting member in conjunction therewith, typically sewn into a special pocket on the fabric item provided specifically for this purpose. By way of example, filtration tubes manufactured from various fabrics, including woven fiberglass, are used for filtering through gasses and other exhausts so as to remove filterable contaminants therefrom prior to dumping the exhaust into the atmosphere. Such tubes typically have a round cross section of approximately 1 foot in diameter and may have a length of or feet or more.

Prior art filtration tubes are fabricated by first starting with an appropriate sized strip of material and sewing the strip into the shape of a tube by creating a single longitudinal seam. Rings of steel or other metal or plastic are then formed into the appropriate diameter and welded or otherwise fixed in the desired shape. A plurality of strips of material having a length somewhat greater than the circumference of the tube and a width of just a few inches are then prepared. The tube is placed on a sewing machine, a ring placed over the tube and the separate strips placed around the circumference of the tube and over. the ring and sewn in position on each side of the ring so as to entrap the ring therein. Obviously, in order to do this, the separate strips with the ring therein have to be sewn on a long arm sewing machine, and the operator of the machine must literally stuff the material of the tube on the arm of the sewing machine to provide access to the desired section of the tube for stitching the ring in place. Thus, on larger tubes, 5 or 10 feet of the tube must be bunched up on the arm and rotated as the stitching progresses around the periphery of the tube for a particular ring. Typically, the tube is removed from the machine and reversed to provide access to the portion of the tube adjacent the second end. Obviously, the length of the tube which can be sewn on a particular machine is a function of the length of the arm of the machine and, in general, special machines are required for this rate strips forming the peripherial pocket enclosing the ring require a substantial amount of material. The material cost alone for tubes for use at elevated temperatures, e.g., woven fiberglass, will increase the cost of the tubes by a matter of a few dollars. Similarly, the time consuming operation of cutting and sewing these pieces in the appropriate position after the longitudinal stitch is made to form the tube also contributes significantly to the overall cost of the tube. Thus, some form of mechanical support for sewing into the tube which does not require additional fabric beyond that required for the tube itself, and preferably which could be sewn onto the fabric prior to the forming of the tube by the longitudinal stitch, would result in a substantial reduction in the cost of such items and in the reduction in material and time required to sew up the completed item. Further, such a support would substantially eliminate the need for the special equipment now required to handle particularly the larger tubes.

BRIEF SUMMARY OF THE INVENTION A selfishaping support for the mechanical support of flexible materials, such as tubular shaped fabric members used for filtration tubes. The support may be comprised of a T-shaped extruded member having a plurality of notches cut in the leg of the T-shape and a plurality of slots punched in each side of the topof the T- shape. The support may be sewn to the fabric in the fiat condition by stitching through the plurality of slots punched in the top of the T, leaving a predetermined amount of fabric overlapping the ends of the support. The support is later rolled into a closed shape by bending so as to close at least a portion of the notches in the leg. Equally spaced notches may be used to ultimately provide a substantially round support, whereas nonequally spaced notches may be used to provide supports of configurations other than :round. A special clip is disposed for retaining the ends of the ring, one with respect to the other. Thus, the fabric tube may be sewn into a shape of a conduit by a longitudinal stitch, and the support bent and locked in desired configuration as each support is approached during longitudinal sewing operation. Various embodiments are disclosed, including an embodiment in which the ends of the support are disposed in substantial separation when the support is bent to the desired shape allowing the passage of a sewing machine head therebetween. In such a configuration, a special elongated clip is used to bridge the gap between the ends and retain the ends one to the other. Various other embodiments are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a prospective view, partially cut away, of a portion of the filtration tube using the self-shaping supports of the present invention.

FIG. 2 is a top view of the support member for the self-shaping support shown in FIG. 1.

FIG. 3 is a side view of the self-shaping support shown in FIG. 2.

FIG. 4 is a view of the self-shaping support after the support is bent into a closed configuration.

FIG. 5 is a cross section taken along lines 5-5 of FIG. 4 showing one means for retaining the ends of the support, one to the other.

FIG. 6 is a side view of the retaining means taken along lines 6-6 of FIG. 5. 1

FIG. 7 is a cross section, similar to the cross section of FIG. 5, showing an alternate embodiment for the means of retaining theends of the support.

FIG. 8 is a top view of the alternate embodiment of FIG. 7.

FIG. 9 is a partial cross sectional view of the two ends of the support member after it is bent into the closed configuration, illustrating a further alternate embodiment for the retaining means.

FIG. 10 is a top view of a section of fabric having the self-shaping support of the present invention sewn thereon.

FIG. 11 is an illustration of the manner in which a filtration tube using the self-shaping support of the present invention may be sewn.

FIG. 12 is a view taken along lines 12-12 of FIG. 11 illustrating the resulting seam and the clip retaining the two ends of the self-shaping support.

FIG. 13 is a top view of an alternate embodiment of the self-shaping support.

FIG. 14 is a side view of the alternate embodiment of FIG. 13.

FIG. 15 is a cross section of the alternate embodiment of FIG. 13.

FIG. 16 is a view of the alternate embodiment of FIG. 13 after that embodiment has been bent to its predetermined shape.

DETAILED DESCRIPTION OF THE INVENTION First referring to FIG. 1, a section of a typical filtration tube employing a self-shaping support incorporating the principles of the present invention may be seen. The filtration tube, generally indicated by the numeral 20, is characteristically a flexible, pervious material such as cotton, nylon and the like, and for high temperature uses, may be a woven fiberglass material. The fabric, indicated by the numeral 22, has a single longitudinal seam forming the sheet material into a conduitlike member. Support members, such as support member 26, are stitched to fabric 22 so as to provide mechanical support for the flexible material at various positions along the length of the conduit and to maintain the flexible material substantially in its desired shape in the absence of an internal flow and pressure applied thereto.

Now referring to FIGS. 2 and 3, a top view and a side view, respectively, of the support member 26 as it is fabricated in the preferred embodiment of the invention may be seen. Reference is also hereby made to FIG. 5, which shows the cross section of the support member. In this embodiment, the support member 26 is generally comprised of a T-shaped member having a top member 28 and a leg 30. The support member 26 in the preferred embodiment is fabricated from aluminum extruded in the basic T cross section. The extruded member is cut to the desired length and a plurality of notches 32 are punched therein. The purpose of these notches are to define locations along the length of the support member having grossly reduced resistance to bending so as to allow bending into a closed shape, with the number and size of the notches being selected so that when bent into a closed shape, at least a portion of each notch will be substantially closed, thereby resisting substantial deformation from the predetermined closed shape. In the embodiment shown in FIG. 1 and in detail in many of the following figures, the support member is designed to bend into the general shape of a ring, and therefore, substantially identical, equally spaced notches are provided in the extruded member.

In the top of the T section, that is in top member 28, a plurality of slots 34 on each side of leg 30 are pro vided. These slots, generally elongate in planform, provide an opening in the top 28 so as to allow stitching of the support to the material to be supported thereby.

When a bending moment is applied to the ends of the self-shaping support, the support will bend into a closed configuration having a cross section determined by the nature and disposition of the slots 32. Thus, as may be seen in FIG. 4, the slots 32, which in this embodiment are V slots, are substantially closed, and once the two ends of the support member are retained one to the other, little deformation of the support member from the round configuration of this embodiment may occur. In this regard, it is to be noted that though various loads in the support member, when in the closed configuration, tend to encourage certain of the slots 32 to be opened, the same loads tend to encourage other slots 32 into tighter closure and thereby resist the tendency to deform in response to the loads. Obviously, if there are N identical slots in the self-shaping member, each slot must allow bending of the member through an angle of approximately 360 divided by N in order for the member to be easily shaped into the desired closed configuration and to effectively withstand deforming forces after the ends thereof are retained one to the other.

Various means may be used to retain the two ends of the self-shaping support. By way of example, FIGS. 4, 5 and 6 illustrate one of such means. In this embodiment, a pair of holes 36 are punched or drilled in each end of the member 26. Subsequently, when the member is bent into the closed shape, a plate-like member 38 is placed on either or both sides of the legs 30 of the T cross section and bolted thereto by means of bolts 40 and nuts 42. The plate 38 provides both a connecting means between the two ends and a rigidifying means for maintaining the relative angular disposition between the two ends in the presence of distorting forces.

While the above described method of maintaining the two ends in fixed relative dispostion is easily and inexpensively manufactured, it has the disadvantage of being somewhat time consuming in application. Specifically, since the ends of the self-shaping support are not to be retained one to the other until the longitudinal seam in the filtration tube is being stitched, access to the ends of the support is somewhat limited, and the application and tightening of nuts and bolts is awkward, particularly for a sewing machine operator. Therefore, in the preferred embodiment the clamps of FIG. 7 and 8 are used. FIG. 7 is a cross section of the self shaping support similar to that of FIG. 5, showing the clamp 44 engaging the legs 30 of the support, and FIG. 8 is a view of the support member 26 taken from the same direction as that of FIG. 2 after the support member has been bent into the closed shape. In this embodiment, the two ends of the support member, designated in these figures as member 26a, each have a pair of dimpled areas 46 generally disposed in the same position as holes 36 in the previously described embodiment. The dimpled areas 46 are formed by partially punching member 30 so as to cause a depression on one side of the member and a raised area on the opposite side without shearing or cutting free the dimpled material. The clamp 44 is provided with four mating dimples 48 on one side thereof and a hole 50 on the other side thereof so as to mate with both the depression on one side of the legs of the T and the protrusions on the other side of the legs.

Member 44 is generally fabricated from a spring-like material such as a spring steel or beryllium copper. The top edges 52 of member 44 are flared outward against the legs of the support 26a and will thereby automatically be yieldably encouraged into separation until snapping into position with respect to the dimples 46.

As a further aid in placement of clamp 44, a slot or opening 54 may be provided in one side 56 of the clamp generally aligned with the two ends of the support so that the clamp is divided into two U-shaped spring-like members. In this manner, each end of the clamp 44 may be separately yieldably opened to receive the end of the support member. This allows the placement of the clamp on one end of the support member after the member has been stitched to the fabric but before the member is bent in the closed shape. The slot 54 does not substantially weaken the clamp since the opposite leg and the base of the U-shaped clamps are solid.

Of course, other means may be used to provide a quick attachment and retention at the two ends of the support, such as shown in FIG. 9 wherein a plate 58 having a plurality of hook-like members 60 projecting therefrom may be snapped into the holes 36 in support 26, with the shank of hook-like member 60 engaging the side of the holes 36 adjacent the ends of the support to prevent the separation thereof.

Having now described the general construction of the self-shaping support of the present invention, the manner of use thereof shall now be described in greater detail. In FIG. 10 a strip of flexible material 22 having a width which is slightly greater than the circumference of the finished filtration tube 20 can be seen. At various positions along this strip of material the self-shaping support 26 is stitched through the slots 34 provided therein for that purpose. Thereafter, the strip of mate rial 22 is placed on a sewing machine of the type having the arm 60 projecting forward towards the operator, and adapted to sew material as the material flows in the direction indicated by the arrows. In FIG. 11, the sewing machine arm 60 is shown only to the extent necessary to indicate the arrangement of the sewing machine in relation to the direction of stitching, such sewing machines being well known in the prior art. The material 22 is then placed generally under the arm 60, and as sewing progresses, is raised upward and formed into the closed shape, and is stitched in the closed shape as it passes under the head of the sewing machine generally located in the area 62. As the stitching approaches each of the self-shaping support members 26, the support members are bent into the substantially closed configuration and the means for retaining the two ends of the member in fixed relation one to the other is at tached thereto. Thus, as a support member 26 passes the stitching head, generally indicated in the area 62,

the support and seam may appear as shown in FIG. 12. The extra material at the end of support 26 shown in FIG. 10 is generally folded so as to form one of the conventional stitched seams, and the extent of overlap, etc., is predetermined so that the stitched circumference or periphery of the filtration tubes is substantially the same as that of the self-shaping support when bent and retained in the closed condition.

In the embodiment shown heretofore, the two ends of the support member may be touching or substantially touching when bent in the closed form, and the short section of longitudinal seam in the area of each of support members 26 is generally left unstitched. It is to be noted that the self-shaping support may be bent into a predetermined and controlled shape having a substantial gap between the two ends of the support, such as by way of example, a gap as wide as the foot of the sewing machine so that continuous sewing of the longitudinal seam may be accomplished. In such an embodiment, the retaining means would be adapted to bridge the gap between the two ends so as to form a closed support assembly. Such an embodiment, is shown in FIGS. 13 through 16. In particular, the specific embodiment shown therein is substantially different than the previously disclosed embodiment in that a self-shaping support of a configuration other than round, and with a different cross section, is shown, together with the elongated clamp to retain the two ends in the desired disposition. (Still other cross-sections, such as, by way of example, a right angle member, may be used, with one surface slot to accommodate for bending notches, and the other surface slotted for stitching t0 the fabric.) Thus, FIGS. 13 and 14 are top and side views, respectively, of the support member 26b, and FIG. 15 is a cross section of the support member taken along lines 15-15 of FIG. 13. It may be seen that in this embodiment the cross section of the support member has been changed to that of a channel member. Also, the notches 32a in the support member 26b to naturally bend into a shape other than round, specifically, into the generally rectangular shape shown in FIG. 16. Also, the use of the channel cross section results in a significant separation of the side-wise extend ing members 60 and the slots 34a therein. This further separates the stitching used to stitch the support member to the fabric, thereby providing better support and a less concentrated strain thereon.

While in the previously described embodiment the stitching of the longitudinal seam was interrupted at each support member, the embodiment of FIGS. 13 through 16 does not require such interruption. Specifically, the ends 62 of the self-shaping support are disposed with considerable separation when the support is bent into the desired shape, thus allowing the passage of the foot of the sewing machine therebetween. The ends 62 may be supported in relation to each other by any convenient means such as those previously described. In particular, in FIG. 16, clamp 44a, substantially the same in construction and function as clamp 44 shown in FIGS. 7 and 8, may be seen. The clamp 44a is generally of an elongate construction as compared with clamp 44, and further, the dimples 46a are placed in greater separation so as to provide an improved rigidity to withstand the forces that it may be subjected to.

There has been described herein a self-shaping support member with end clamps which may be used for the support of flexible material such as is used in filtration tubes and the like. The self-shaping support is readily stitched to the material to be supported thereby and quickly and easilybent to the desired predetermined shape during the stitching of the fabric. No additional fabric is required, other than the. fabric used for the members to be supported, and closed fabric members of substantially any length may be stitched on industrial sewing machines of a type generally found in facilities for fabricating sewn articles. A self-shaping support may be fabricated sewn articles. A self-shaping support may be fabricated from an extruded member which is subsequently punched to provide the means for receiving stitches and to accommodate the bending to the desired shape. While V notches are shown in the embodiment disclosed herein so as to define positions of substantially reduced bending resistance, it is to be understood that notches of other configurations are also suitable for such use, though, in general, the notches should be designed so that at least the outer portion of the notch substantially closes when the member is bent to the desired shape. Thus, while the invention has been particularly shown and described with reference to the preferred embodiments thereo, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.

I claim:

1. A self shaping support for supporting flexible material comprising: a support member with first and second ends and a retaining means, said support member being an elongate member having at least one sidewise protruding segment having a first surface for disposition against the material to be supported, said protruding segment being integral with a second segment, said second segment having a substantial projection in a direction perpendicular to and away from said first surface, said sidewise protruding segment having a plurality of slots along the length thereof, said second segment having a plurality of notches generally perpendicular to the length of said second segment, each extending approximately to said sidewise protruding segment whereby said support will bend to a predetermined shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said predetermined shape.

2. The self shaping support of claim 1 wherein said second segment is substantially at a right angle to said first segment.

3. A self shaping support for supporting flexible material comprising: a support member with first and second ends and a retaining means, said support member being an elongate member having a pair of sidewise opposingly protruding segments each having a first surface in a common plane for disposition against the material to be supported, said protruding segments being integral with a third segment, said third segment having a substantial projection in a direction perpendicular to and away from said first surface, said sidewise opposingly protruding segments each having a plurality of slots along the length thereof for fastening to flexible material prior to bending said support into its final shape, said third segment having a plurality of notches generally perpendicular to the length of said third segment, each extending approximately to said sidewise opposingly protruding segments whereby said support will bend to a predetermined shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said predetermined shape.

4. The self shaping support of claim 3 wherein said notches generally perpendicular to the length of said third segment are V-shaped notches having the apex thereof adjacent said first and second segments.

5. The self shaping support of claim 3 wherein each of said sidewise opposingly protruding segments are substantially flat segments, and said plurality of slots therein are disposed in a line adjacent and parallel to the edge thereof.

6. The self shaping support of claim 3 wherein said support member is a T-shaped member formed from an extruded member.

7. The self shaping support of claim 6 wherein said support member has at least one depression in a side surface of the leg of said T-shaped member adjacent each end thereof, said depressions resulting in a corresponding protrusion on the opposite side surface, and said retaining means is a clamp having a C shape so as to slip over the ends of said leg of said T-shaped member and elastically grip the side surface thereof, said clamp having at least two holes therein disposed so as to engageable by said protrusions to retain said clamp with respect to said support member.

8. A self shaping ring for stitching onto flexible material prior to bending to provide a support ring therefor comprising an elongate T-shaped member and a locking means, said T-shaped member having a first segment having a substantially flat surface forming the top of the T and a second segment forming the leg of the T, said first segment having a plurality of elongated slots along the length and adjacent the two sides thereof for receiving stitches therein, said third segment having a plurality of notches generally in and perpendicular to the length of said third segment, each extending approximately to said second segment whereby said support will bend to a predetermined substantially circular closed shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said substantially closed shape.

9. The self shaping ring of claim 8 wherein said slots generally perpendicular to the length of said second segment are V-shaped notches having the apex thereof adjacent said first segment.

10. The self shaping ring of claim 9 wherein said T- shaped member has at least one depression in a side surface of said second segment adjacent each end thereof, said depressions resulting in a corresponding protrusion on the opposite side surface, and said retaining means is a clamp having a C shape so as to slip over the ends of said second segment and elastically grip the side surface thereof, said clamp having at least two holes therein disposed so as to be engageable by said protrusions to retain said clamp with respect to said T- shaped member. 

1. A self shaping support for supporting flexible material comprising: a support member with first and second ends and a retaining means, said support member being an elongate member having at least one sidewise protruding segment having a first surface for disposition against the material to be supported, said protruding segment being integral with a second segment, said second segment having a substantial projection in a direction perpendicular to and away from said first surface, said sidewise protruding segment having a plurality of slots along the length thereof, said second segment having a plurality of notches generally perpendicular to the length of said second segment, each extending approximately to said sidewise protruding segment whereby said support will bend to a predetermined shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said predetermined shape.
 2. The self shaping support of claim 1 wherein said second segment is substantially at a right angle to said first segment.
 3. A self shaping support for supporting flexible material comprising: a support member with first and second ends and a retaining means, said support member being an elongate member having a pair of sidewise opposingly protruding segments each having a first surface in a common plane for disposition against the material to be supported, said protruding segments being integral with a third sEgment, said third segment having a substantial projection in a direction perpendicular to and away from said first surface, said sidewise opposingly protruding segments each having a plurality of slots along the length thereof for fastening to flexible material prior to bending said support into its final shape, said third segment having a plurality of notches generally perpendicular to the length of said third segment, each extending approximately to said sidewise opposingly protruding segments whereby said support will bend to a predetermined shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said predetermined shape.
 4. The self shaping support of claim 3 wherein said notches generally perpendicular to the length of said third segment are V-shaped notches having the apex thereof adjacent said first and second segments.
 5. The self shaping support of claim 3 wherein each of said sidewise opposingly protruding segments are substantially flat segments, and said plurality of slots therein are disposed in a line adjacent and parallel to the edge thereof.
 6. The self shaping support of claim 3 wherein said support member is a T-shaped member formed from an extruded member.
 7. The self shaping support of claim 6 wherein said support member has at least one depression in a side surface of the leg of said T-shaped member adjacent each end thereof, said depressions resulting in a corresponding protrusion on the opposite side surface, and said retaining means is a clamp having a C shape so as to slip over the ends of said leg of said T-shaped member and elastically grip the side surface thereof, said clamp having at least two holes therein disposed so as to engageable by said protrusions to retain said clamp with respect to said support member.
 8. A self shaping ring for stitching onto flexible material prior to bending to provide a support ring therefor comprising an elongate T-shaped member and a locking means, said T-shaped member having a first segment having a substantially flat surface forming the top of the T and a second segment forming the leg of the T, said first segment having a plurality of elongated slots along the length and adjacent the two sides thereof for receiving stitches therein, said third segment having a plurality of notches generally in and perpendicular to the length of said third segment, each extending approximately to said second segment whereby said support will bend to a predetermined substantially circular closed shape substantially closing each of said notches in response to a bending moment applied to the ends thereof, and said retaining means is a means for retaining the said first and second ends in a fixed relation when said support is bent to said substantially closed shape.
 9. The self shaping ring of claim 8 wherein said slots generally perpendicular to the length of said second segment are V-shaped notches having the apex thereof adjacent said first segment.
 10. The self shaping ring of claim 9 wherein said T-shaped member has at least one depression in a side surface of said second segment adjacent each end thereof, said depressions resulting in a corresponding protrusion on the opposite side surface, and said retaining means is a clamp having a C shape so as to slip over the ends of said second segment and elastically grip the side surface thereof, said clamp having at least two holes therein disposed so as to be engageable by said protrusions to retain said clamp with respect to said T-shaped member. 